Thick butt element



20, 1940. (1R, ECKERT 2,212,341

THICK BUTT ELEMENT original Filed Nov. 25, 1951K lNvENToR CLA RE/vce E. ECA/5er ATTORN EY lao ' or the shingle of Fig. a;

lPatented Aug. 20, 19u40 UNITED STATES THICK BUTT ELEMENT Clarence R. Eckert, Englewood, N. J., assignor,

by mesne assignments, to The Patent and Licensing Corporation, New York, N. Y., a corporation of Massachusetts Original application November 25, 1931, Serial Divided and this application October 12, 19,36, Serial No. 105,231

10 Claims.

This invention relates to iiexible composition shingles and processes ofmaking same, and more particularly, to thick butt strip shingles of the felt base type, coated with waterproofing material,

5 surfaced with granular material, and having the tab portions provided with an additional coating of waterproofing material, and a surfacing of v granular material. This application is a division of my Patent No. 2,074,684, dated March 23, 1937.

One object of this invention is to provide a durable thickv butt shingle of attractive appearance which may be laid with other like shingles in overlapping courses to impart to the roof or other surface to which they are applied an irregular or hand-made effect.' Another object is to provide a composition shingle which may be laid to provide a more durable weather-resistant roof than composition shingles heretofore known. Other objects and advantages of this invention will appear from the following detailed description, taken in connection with the accompanying drawing, in which lFig. 1 is a fragmentary side elevation, somewhat diagrammatic in character, indicating the 25 steps involved in the formation ofthe thick butt shingle of this invention;

` Fig. 2 is a fragmentary plan view of a coated and surfaced felt base, prior to the cutting thereof into strip shingles; Fig. 3 is a plan view of a shingle embodying the invention;

` Fig. 4 isa vertical section through a. tab portion employed in applying the waterproofing material to'form the thick butt shingle of Fig. 3.

Fig. 6 is a fragmentary plan view of a number of shingles arranged in abutting relationship and j inv overlapping courses.

Referring to the drawing, reference numeral I I i `(Fig.1) indicates `the usual felt base made of rag fiber, paper stock, or other fibrous material and l thereafter saturated 'with bituminous material,l

as "is well known in the art. The saturated felt I4 is passed between the coating-.rolls 2, 3, -f *the latter of which rotates ini a coating bath 4 "containing asphalt or other bituminous material.

j-[Waterproofing material may also befed lto the A"coating roller 2, or other form df coating appa- 'ratus `might be used-to coat both sides of the felt .base. The coated base passes overvg'uide roll 5, v-bringing the cementitious coated side under hopper 6 containing granular material, such as crushed slate, rock o r other surfacing material. 'lihey granular material from hopper i is showered VvFig. 5 shows a side elevation of the coating roll by means of the usual distributing roll 'I onto they coated felt base, completely covering the coating.

The thus surfaced base is then passed about roll 8 which serves to partially embed the granular material in the base. The surfaced base then passes under hopper 9 which applies anti-stick material, such as mica dust, to the rear side, rendering this side non-cementitious. In .the continued passage of the base I about rolls 8 land 9, excess surfacing material falls oil therefrom respectively into hoppers 6 and 9', whence the granular material was delivered to the base I. The sheet their passes over the drying 'rolls I0 to I5 and from the roll I5 is passed between the pull f rolls I6, I1, which may be suitably driven, the pull rolls I6 rotating ata slightly greater peripheral speed than the rolls II to provide a slack of material between the rolls I6 and I'I. From the rolls I1, the coated and surfaced strip is fed to a coating appliance indicated generally by the reference numeral I8.

Coating device I8 may consist of a tank I9, having rotatablyA mounted therein a coating roll 2l of special construction. This roll is designed to apply coating material, such asi asphalt or other bituminous waterproofing composition to selected spaced areas of the felt base. The size and shape of the selected areas may be varied to produce shingles having tabs or individual shingle-simulating portions of' various shapes and of different lengths and/or widths. In the embodiment of the invention shown in Fig. 5, a coatingvv roll having series of spaced platen portions 22 is employed. The platen portions 22 are disposed in parallel rows which run both longitudinally and circumferentially of the roll. The individual platens 22 in each circumferential row, indicated by the reference numeral 23, are preferably identical in shape. The individual platens in' each longitudinal row, indicated by the reference numerals 2|, are of different widths, of the same length, and are spaced different distances apart.- In the embodiment shown in Fig. 5, intermediate platen 25 is the widest, platens 26, adjacent to platen 25, are of materially less width than platen 25.. The left hand `end platen 21V isvof somewhat less width than the platen 26 adjacent thereto and the right hand end platen 21 is of somewhat greater width than the Aplaten 26 adja cent thereto. Passage of the surfaced sheet over the coating roll shown in Fig. 5resu1ts in application of the waterproofing material on selected spaced areas arranged in transverse rowsv 2l of the sheet, as indicated in Fig. 2, the individual areas of each row being of the same length but of Rthe granular material in hopper 6 is supplied to hopper 31.

If it is-desired to make adjacent tab portions of the shingle of different colors, partitions may be inserted in hopper 31 and different colored granular material supplied to the dierent compartments of the hopper. Granular material is showered from hopper 31 by means of the usual distributing roll 38 onto the coated sheet below. The granular material adheres only to the cementitious coated portions and does not adhere to the portions of the base between the transverse coated stripes or to the uncoated portions between the selected coated areas constituting the transverse coated bands or stripes. From the surfacing hopper 31, the sheet having the granular material thereon passesaround roll 39, which functions to partially embed the granular material in the coated portions.

From roll 39 the sheet passes over reversing roll 4I. The surfaced sheet in its passage about roll 4I causes the excess granules to fall from the sheet back into the hopper 31. The sheet then passes over drying rolls 42, 43, 44, and 45, and thence to the cutting rolls 46`, where it is cut into shingle elements.

The base of Fig. 2- may be cut transverselyalong the lines indicated by the reference numeral 69 to form the strip shingle shown in Figs. 3 and 4. This shingle is composed of a felt base 54, provided with a seal back coating 55 rendered noncementitious by the application of mica dust 56 thereto. The face of the element is substantially completely covered by coating 51, which is surfaced with granular material 58. A second coating 59 covers spaced selected areas of the portion of surfacing 58 intended to be exposed, leaving uncoated tab-defining depressions or slots 6I between these areas. It will be observed that the double-coated area 58a is considerably greater than that of the double coated areas 58h, 53o, 58d and 58e. As shown in Figs. 3 and 4, the spaced selected areas differ in width and are separated by slots of different widths. A second surfacing 62 of granular material is partially embedded in the coating 59.

The shingle has, at the forward thickened edge, an integral thin portion 1I which is disposed the full length of the element. The portion.l 1 I, when the elements are laid in overlapping courses, accentuates the thickness -of the thickened portion of the element to the observer.

The shingles are preferably arranged in overlapping courses as shown on Fig. 6. The elementsv of each course may be laid in abutting relation or in slightly spaced relation so as to form a slot between contiguous shingles. The overlying course of elements is preferably laid with the forward edges 18 overlapping the upper edges 19 of the thickened portions of the underlying elements andthe relatively wide tab portions 58a overlying the joints 90 between the abutting or separated edges of the shingles ofthe underlying course. It will be observed that the wide thickened tab portions 58a increase the strength and weather-resistant properties of the joints between underlying shingles, and hence provide adequate reinforcing for such joints, the

weakest points of shingle roofs. -The forward thickened edge of each element is exposed to view and the shingle imparts to the observer an appearance of thickness and solidity, accentuated bythe portion 1 I.

It will be noted that the shingle of this invention involves no waste in its'manufacture. Further, a simple transverse cutting knife only is necessary to produce the same, and while it resembles in appearance the usual strip shingle having tabs separated by slots, slot cutting knives and mechanism for removing the material -cut out to form the `slots are not necessary for the manufacture of this shingle. Owing to the differences in shape andl dimensions of the exposed selected areas of each element, the shingle of this invention avoids thedrab and monotonous appearance of existing strip shingles and imparts a variegated, hand-made, or thatched effect to roofs or other surfaces to which they are applied. Furthermore, it will be noted the ltab simulating portions are so arranged that when the shingles are laid upon overlapping courses with the joints of the shingles of one course staggered with respect to those of a contiguous course the widest tab portions of the overlying shingles overlie the joints between the underlying shingles with the joints disposed substantially midway between these wide tab portions j' hence maximum protection of the joints is afforded.

As an alternative method, I may omit the first mineral surfacing operation carried out with the hopper 6 and distributing roll 1, surfacing with grit only the limited thick areas resulting from the operation of the roll 2I by means of hopper 31 and distributing roll 38. If I operate in this manner, I find it advantageous to coat the upper surface of the web leaving roll 5 with an anti-stick ing material such as a film of soap solution, which will prevent the sheet from sticking to the rolls, but will not prevent the asphalt pads of roll 2'I from applying asphalt to the sheet in spaced selected areas. The exposed tab portion of shingles made by this alternative process have substantially the same appearance as those previously described, but the shingles lack the surfac-v ing 58 having in lieu thereof a coating of antistick orl non-cementitious material.

While a preferred embodiment of the invention has been described herein, it will be understood that this invention is not confined to the form disclosed but may loe-variously` embodied within the scope of the appended claims.

What is claimed is: r

1. A shingle adapted to be laid in overlapping courses with other like shingles, comprising a felt base coated with bituminous material and an additional coating of bituminous material applied to selected areas of the portion of the surface of the base intended to be exposed, said selected areas being spaced from the lower edge 'of the felt base to leave an integral portion of the coated felt base along the lower edge thereof uncovered by said additional coating.

2. A shingle adapted to be laid inoVerlapping courses with other like shingles, comprising a. iibrous base coated with bituminous material and surfaced with granular material, an additional coating of Abituminous material applied to spaced base intended to be exposed, said selected areas being of various sizes and shapes and spaced from the lower edge of the felt base, and a surfacing of grit partially embedded in said selected areas, the grit surfacing on adjacent selected areas being of contrasting color.

,selected areas of the portionof the surface of the 3. A roong or siding strip comprising a felt base saturated with waterproong material and having shingle simulating portions, a coating of asphalt covering the entire upper surface of said base and having embedded therein a surfacing of granular material, and a substantial thickening and weight imparting overlay coating of asphalt having embedded therein a surfacing of granular material, said overlay coating covering all of that portion of shingle simulating portions of the roofing or siding strip which is to project beyond the ends of the shingle simulating portions of the next higher course, except a narrow thick-edge simulating margin along the lower edge thereof.

4. 'A roong or siding strip comprising a felt base saturated with waterproofing material and having shingle simulating portions, a coating of asphalt covering the entire upper surface of said base and having embedded therein a surfacing of graular material of one color, and a substantial thickening and weight imparting overlay coating having embedded therein a surfacing of granular material of another color, said overlay coating covering all of that portion of the shingle simulating portions of the roofing or siding strip which is to project beyond the ends of the shingle simulating portions of the next higher course except a narrow thick-edge simulating margin along the lower edge thereof.

5. A roofing or siding strip comprising a felt base saturated with paterprooflng material, a coating of asphalt covering at least the exposed portion of said strip when laid upon the roof and having embedded therein at least in the exposed portion thereof in the roof, a surfacing of granular material and a substantial thickening and weight imparting overlay coating of asphalt having embedded therein a surfacing of granular material, said overlay coating covering at least the major portion of the area of that portion of the initially coated roong or siding strip which is to project beyond th next higher course, except a narrow thick-edge simulating margin along the lower edge thereof.

6. A roofing or siding strip comprising a felt base saturated with waterproofing material, a coating of asphalt covering the entire upper surface of said base and having embedded therein ay surfacing of granular material, and a substantial thickening and weight imparting overlay coating of asphalt having embedded therein a surfacing of granular material, said overlay coating covering that portion of the initially coated roofing or siding strip which is to project beyond the next higher course, leaving uncovered a narrow thickedge simulating margin along the lower edge thereof.

'7. A roong or siding strip comprising a felt base saturated with waterproofing material, a

coating of asphalt covering the entire upper surface of said base and having embedded therein a surfacing of granular material of one color, and a substantial thickening and Weight imparting overlay coating of asphalt having embedded therein a surfacing of granular material of another color, said overlay coating covering that portion of the initially coated roofing or siding strip which is to project beyond the next-higher course, leaving uncovered a narrow thick-edge simulating margin along the lower edge thereof.

8L A roofing or siding strip comprising a felt base saturated with waterproofing material, a coating of asphalt covering the entire upper surface of said base and having embedded therein a surfacing of granular material, and a substantial thickening and weight imparting overlay coating of asphalt having embedded therein a surfacing of granular material, said overlay coating covering that portion of the initially coated roofing or siding strip which is to project beyond the next higher course, leaving uncovered a narrow margin along the lower edge thereof, the color of said narrow strip so contrasting with that of the remainder of the exposed part of the roong or siding strip as to produce a thick butt shadow effect.

9. A roong or siding strip comprising a felt base saturated with waterproofing material, a coating of asphalt covering at least the exposed portion of said strip when laid upon the roof and having embedded therein at least in the exposed portion thereof in the roof, a surfacing of granular material and a substantial thickening and weight imparting overlay coating of asphalt having embedded therein a surfacing of granular material, said overlay coating covering that portion of the initially coated r'oong or siding strip which is to project beyond the next higher course, leaving uncovered a narrow thick-edge simulating margin along the lower edge thereof.

10. A roofing or siding strip comprising av felt base saturated with waterproofing material, a coating of asphalt covering at least the lower part of the exposed portion of said strip when laid upon the roof and having embedded therein, at

least in that part of said coating which is exposed when the overlay coating has been applied, a surfacing of granular material, and a substantial thickening and weight imparting overlay coating of asphalt having embedded therein a surfacing of granular material, said overlay coating covering a part of said initial coating and that portion of the roofing or siding strip which is to project beyond the next higher course, leaving uncovered a narrow thick-edge simulating margin along the lower edge thereof.

` CLARENCE R. ECKERT. 

